czech sport aircraft SPORTCRUISER Maintenance Manual
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czech sport aircraft SPORTCRUISER Maintenance Manual

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Download this manual See also: Maintenance Manual, Operating Handbook
This document contains information necessary for operation and maintenance of the airplane
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Summary of Contents for czech sport aircraft SPORTCRUISER

  • Page 1 This document contains information necessary for operation and maintenance of the airplane according to LSA regulation. Á Á Č Č Á Á Č Č www.czechsportaircraft.com...
  • Page 2 INTENTIONALLY LEFT BLANK...
  • Page 3 RECORD OF REVISIONS Rev. Date and Reason for revision Changed pages Issue date signature initial 01/2007 Design changes 01/2008 See list of effective pages Ailerons and trims deflections, coolant 04/2008 See list of effective pages operation limits Operating liquids 02/2009 See list of effective pages Reissue 04/2009...
  • Page 4 LIST OF EFFECTIVE PAGES Chapter Page Date Chapter Page Date 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009 04/2009...
  • Page 5 Chapter Page Date Chapter Page Date 04/2009 04/2009 10-18 04/2009 04/2009 10-19 04/2009 04/2009 10-20 04/2009 04/2009 10-21 04/2009 04/2009 10-22 04/2009 04/2009 10-23 04/2009 04/2009 10-24 04/2009 04/2009 10-25 04/2009 04/2009 10-26 04/2009 04/2009 8-10 10-27 04/2009 04/2009 8-11 10-28 04/2009 04/2009...
  • Page 6 Chapter Page Date Chapter Page Date 04/2009 15-1 04/2009 15-2 04/2009 15-3 04/2009 15-4 04/2009 15-5 04/2009 15-6 04/2009 15-7 04/2009 15-8 04/2009 15-9 04/2009 15-10 04/2009 15-11 04/2009 15-12 04/2009 15-13 04/2009 15-14 04/2009 15-15 04/2009 15-16 04/2009 15-17 04/2009 15-18 04/2009...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Chapter 1 - General ..................1-1 Chapter 2 - Limitations/Maintenance checks ..........2-1 Chapter 3 - Fuselage ................... 3-1 Chapter 4 - Wing..................4-1 Chapter 5 - Tail unit ..................5-1 Chapter 6 - Controls ..................6-1 Chapter 7 - Equipment ................
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  • Page 9: Chapter 1 - General

    CHAPTER 1 - GENERAL Introduction ......................1-2 Airplane classification .................... 1-2 1.2.1 Power unit ....................1-2 1.2.2 Main technical data................... 1-3 Airplane manufacturer and type certificate holder ..........1-5 Chapter order......................1-5 1.4.1 Page numbering ..................1-5 Warnings, cautions and notes ................1-5 Definitions and abbreviations.................

  • Page 10: Introduction

    Czech Sport Aircraft a.s. as manufacturer of SPORTCRUISER airplane provides in accordance with requirements of the ASTM LSA regulations information on maintaining airworthiness of the SPORTCRUISER airplane. Information is also contained in the following manuals issued by airplane manufacturer or by manufacturers of equipment used on the...

  • Page 11: Main Technical Data

    Main technical data Wing span ................8.81m (28.90 ft) • area ................12.3m (132.3 sqft) • MAC ................1500mm (59.1 in) • wing loading .............. 49kg/m (10.0 lb/sqft) • aileron area .............. 0.46m (4.98 sqft) • flap area ..............0.65m (7.0 sqft) •...
  • Page 12 Fig. 1-1: Three-view drawing GENERAL Date of issue: 04/2009 Revision No. 5 1 - 4...

  • Page 13: Airplane Manufacturer And Type Certificate Holder

    Airplane manufacturer and type certificate holder Office: Production facility: Czech Sport Aircraft a.s. Czech Sport Aircraft a.s. Roháčova 188/37 Na Záhonech č.e. 212 13000 Praha 3 686 04 Kunovice Czech Republic Czech Republic Web page: www.czechsportaircraft.com Phone: +420/572 543 456 E-mail: info@czechsportaircraft.com...

  • Page 14: Definitions And Abbreviations

    Definitions and abbreviations ACCU Accumulator Altimeter Air Traffic Control pressure unit (1 bar = 14,5037 psi) BEACON anti-collision beacon ° C temperature in degree of Celsius (1° C = (° F - 32 ) / 1,8) Calibrated Airspeed COMM Communication transmitter EFIS Electronic Flight Instrument System Emergency Locator Transmitter...
  • Page 15 speed in statute miles per hour Newton - force unit (1 N = 0.225 lbf) Nautical Mile (1 NM = 1852 m) system is switched off or control element is in off-position system is switched on or control element is in on-position Outside Air Temperature system is switched off or control element is in off-position system is switched on or control element is in on- position...
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  • Page 17 CHAPTER 2 – TIME LIMITS/MAINTENANCE CHECKS General ........................2-2 Airframe life limitation .................... 2-2 Engine life limitation ....................2-2 2.3.1 Engine parts with limited life ..............2-2 Ordering spare parts ....................2-2 Terms and list of aircraft regular maintenance works..........2-2 2.5.1 General .....................
  • Page 18 Order spare parts through the Airplane failures card, see section 17.4. Terms and list of aircraft regular maintenance works General Maintenance system serves to maintain flight airworthiness of SPORTCRUISER airplane. Maintenance system is composed of periodic inspections, which must be performed at least in the following intervals:...
  • Page 19 (a) preflight inspection is performed within the scope given in Flight Manual, section 4 (b) propeller inspection after first 5, 20 and 50 flight hours (see Technical description of the propeller) Note: To be performed with a newly installed propeller or with the propeller that was dismantled and reinstalled on the airplane.
  • Page 20 PERIODICAL INSPECTION AFTER FIRST 25 FLIGHT HOURS Aircraft S/N: ………………… Total flight hours: ………… Registration mark: ………………… No. of takeoffs: ………… Page: 1 of 1 Chpt. Prescribed works Made by Checked by Engine and propeller List of performed operations for engine is shown in Maintenance Manual (Line Maintenance) for installed engine List of performed operations for propeller is shown in...
  • Page 21 PERIODICAL INSPECTION AFTER 50 FLIGHT HOURS Aircraft S/N: ………………… Total flight hours: ………… Registration mark: ………………… Total takeoffs: ………… Page: 1 of 1 Chpt. Prescribed works Made by Checked by Engine and propeller List of performed operations for the engine is shown in Maintenance Manual (Line Maintenance) for installed engine.

  • Page 22: Chapter 3 - Fuselage

    ANNUAL PERIODICAL INSPECTION OR INSPECTION AFTER 100 FLIGHT HOURS Aircraft S/N: ………………… Total flight hours: ………… Registration mark: ………………… Total takeoffs: ………… Type of inspection: ………………… Page: 1 of 5 Chpt. Prescribed works Made by Checked by AIRFRAME Fuselage Visually check surface condition including fiberglass parts - loosened rivets, deformation, cracks and some other damage.
  • Page 23 ANNUAL PERIODICAL INSPECTION OR INSPECTION AFTER 100 FLIGHT HOURS Page: 2 of 5 Chpt. Prescribed works Made by Checked by Check horizontal stabilizer attachment and securing. Visually check surface condition - loosened rivets, deformation, cracks and some other damage. Check condition and attachment of the wing tips. Check suspension and free travel of the elevator.
  • Page 24 ANNUAL PERIODICAL INSPECTION OR INSPECTION AFTER 100 FLIGHT HOURS Page: 3 of 5 Chpt. Prescribed works Made by Checked by Check condition and attachment of instruments. Check function and condition of switches and circuit breakers. Check function and condition of throttle controller, choke, Andair valve, heating and ventilation Check condition of labels.
  • Page 25 ANNUAL PERIODICAL INSPECTION OR INSPECTION AFTER 100 FLIGHT HOURS Page: 4 of 5 Chpt. Prescribed works Made by Checked by Check condition and integrity of fuel pumps and hose sleeves in the engine compartment. Visually check for fuel system tightness. Check tightness and condition of fuel pump for occurrence of cracks on the pump body (see 9.4.2) Engine and propeller...
  • Page 26 ANNUAL PERIODICAL INSPECTION OR INSPECTION AFTER 100 FLIGHT HOURS Page: 5 of 5 Chpt. Prescribed works Made by Checked by Navigation/Communication Visually check condition of navigation and communication instruments. Check function of navigation and communication instruments - applied for annual inspection only Check altimeter function - applied for annual inspection only Notes:...
  • Page 27 Lubrication plan After first Every 100 Unit Area of lubrication Lubricant 25 hours hours Engine Throttle control cable on the inlet into Engine oil terminal (in the engine compartment). Choke control cable on the inlet into Engine oil terminal (in the engine compartment). Nose Landing gear leg in the area of mounting Lubrication...
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  • Page 29 CHAPTER 3 FUSELAGE General ........................3-2 Description and operation..................3-2 3.2.1 Front part of the fuselage ..............3-2 3.2.2 Rear part of the fuselage ............... 3-2 3.2.3 Cockpit....................3-4 3.2.4 Baggage compartment ................3-4 3.2.5 Crew canopy..................3-4 3.2.5.1 Canopy .................. 3-4 3.2.5.2 Rear fixed canopy windows ..........

  • Page 30: Chapter 3 Fuselage

    General SPORTCRUISER fuselage is a semimonocoque structure formed by stiffeners and aluminum sheet. The fuselage consists of the front part with the cockpit and the rear part, the integral part of which is the fin. This chapter describes the following: front part of the fuselage •...
  • Page 31 1 … Nose landing gear attachments 4 … Engine mount attachments 2 … Center section of wing 5 … Rudder attachments 3 … Main landing ge ar attachments 6 … Stabilizer attachments Fig. 3-1: Fuselage monocoque 3 - FUSELAGE Date of issue: 04/2009 Revision No.

  • Page 32: Cockpit

    3.2.3 Cockpit The cockpit (see Fig. 3-1) is located in the front part of the fuselage between the bulkheads No.1 and 5. The instrument panel is located on the bulkhead No.2. In the middle of the cockpit there is a middle console with control elements. The cockpit is equipped with two fixed seats. 3.2.4 Baggage compartment Baggage compartment is located between the seats and the bulkhead No.7.

  • Page 33: Removal / Installation

    Removal / Installation 3.3.1 Canopy removal Type of maintenance: line Authorization to perform: Sport pilot or higher Tools needed: socket wrench 7/16” screw driver pliers Follow the Fig. 3-3 at removing of the canopy: (a) Open the canopy (1). (b) Remove securing wires from the gas strut rod ends (2) (c) Disconnect gas struts (3) on both sides of canopy (1).

  • Page 34: Canopy Installation

    3.3.2 Canopy installation Type of maintenance: line Authorization to perform: Sport pilot or higher Tools needed: Socket wrench size 7/16 screw driver pliers At installation of the canopy, follow the Fig. 3-3: (a) Set the canopy on the airplane. (b) Insert the bolts and the nuts into the hinges (6) of the canopy (1). Tighten up the joint. (c) Insert ends of gas strut in to the pin (7) in the fix frame of the canopy and on the foldable frame, secure it with the securing wire (8).

  • Page 35: Strut Installation

    2 … Gas strut rod end 7 … Gas strut pin 3 … Gas strut 8 … Securing wire Fig. 3-4: Removal of the gas strut 3.3.4 Gas strut installation Type of maintenance: line Authorization to perform: Sport pilot or higher Tools needed: pliers At installation of the gas strut follow the Figs.
  • Page 36 At removing of the cabin lock follow the Fig. 3-5 and 3-6: (a) Unscrew the screw (3) attaching the lock (1) to the fuselage wall . (b) Remove out the lock (1). 1 … Lock 2 … Centering pin Fig 3-5: The lock of the canopy (position “Closed”) 1 …...

  • Page 37: Cabin Lock Installation

    3.3.6 Cabin lock installation Type of maintenance: line Authorization to perform: Sport pilot or higher Tools needed: screw driver At installation of the cabin lock follow the Fig. 3-5 and 3-6: (a) Put the lock (1) in to the hole in the fuselage wall. (c) Screw the screw (3) attaching lock to the fuselage wall.
  • Page 38 INTENTIONALLY LEFT BLANK...
  • Page 39 CHAPTER 4 - WING General ........................4-2 Description and operation..................4-2 4.2.1 Wing ...................... 4-2 4.2.2 Wing flaps....................4-3 4.2.3 Ailerons....................4-4 4.2.4 Fuel tanks ....................4-4 4.2.5 Wing lockers ..................4-5 Removal / Instalation ..................... 4-5 4.3.1 Wing removal..................4-5 4.3.2 Wing installation ..................

  • Page 40: Chapter 4 - Wing

    General Sportcruiser wing is an aluminum structure and is equipped with flaps, ailerons and fuel tanks. This chapter describes the structure of: wings • wing flaps • ailerons • fuel tanks • Description and operation 4.2.1 Wing The wing of the airplane is formed from center section of wing made as main and rear spar, which is integrated part of fuselage (Fig.
  • Page 41 1 …Fuel tank 6 ... The main upper and lower 2 ... Aileron attachments of the wing 3 ... Flap 7 ... Rear attachment of the wing 4 ... Winglet 8 ... Aileron trim tab 5 … Position/strobe light 9 ... Wing locker Fig.

  • Page 42: Ailerons

    4.2.3 Ailerons Ailerons (Fig. 4-3) are of aluminum structure consisting of the skin (1) aluminum sheet metal, spar (2) and ribs (3) which are connected by means of riveting. Ailerons are suspended on the rear spar by means of two hinges (4). Moreover the trim tab (5) is installed on the right aileron serving the lateral balance of airplane.

  • Page 43: Wing Lockers

    4.2.5 Wing lockers Wings are equiped with wing locker (9) (Fig. 4-1) placed between ribs No.4 and 5 behind main spar. Capacity of each wing locker is 20 kg (44 lbs). Access doors installed on piano hinge are locked per dzus fasteners. Removal / Installation 4.3.1 Wing removal Type of maintenance: heavy...

  • Page 44: Wing Installation

    4.3.2 Wing installation Type of maintenance: heavy Authorization to perform: Repairman (LS-M) or Mechanic (A&P) . Tools needed: wrench size 7/16 in, 1/2 in phillips #2 screw driver pliers hammer Install the wing according to the following procedure: (a) Before installation clean the attachments and bolts of the outer and center wing from dirt. Preserve bolts and attachments by means of lubricating grease.

  • Page 45: Wing Flap Installation

    Removal of the wing flap according to the following procedure: (a) Open the flap in full position. (b) Disconnect both flap hinges. (c) Remove the flap from the wing. (d) Store the removed flap on a safe place and prevent it from damage. 4.3.4 Wing flap installation Type of maintenance: line Authorization to perform:...

  • Page 46: Check / Adjustment

    Tools needed: wrench size 7/16 in pliers Install the wing flap according to the following procedure: (a) Set the aileron on the wing in to the both hinges. (b) Insert trim tab actuator wires (3) (see Fig. 6-8) going out from wing to the aileron. (c) Insert both bolts in the aileron hinges and screw the nuts on them.

  • Page 47: Chapter 5 - Tail Unit

    CHAPTER 5 – TAIL UNIT General ........................5-2 Description and operation..................5-2 5.2.1 Horizontal stabilizer ................5-2 5.2.2 Elevator with trim tab ................5-2 5.2.3 Fin......................5-3 5.2.4 Rudder ....................5-3 Removal / Installation .................... 5-3 5.3.1 Horizontal stabilizer removal ..............5-3 5.3.2 Horizontal stabilizer installation .............

  • Page 48: General

    General Tail unit of SPORTCRUISER airplane is of all-metal structure and is composed of: horizontal stabilizer • elevator with trim tab • fin surface • rudder • Description and operation 5.2.1 Horizontal stabilizer Horizontal stabilizer (1) (see Fig. 5-1) is of the all-metal structure consisting of the two spars, ribs and aluminum skin.

  • Page 49: Fin

    5.2.3 Fin The vertical fin (1) is of an aluminum structure and is an integral part with the rear part of the fuselage. The fin consists of stiffeners, spar, ribs and aluminum skin. Individual parts are assembled by riveting. The fin tip is made of fibreglass. On the spar are two rudder hinges, lower one (3) and upper one (4).

  • Page 50: Horizontal Stabilizer Installation

    Tools needed: wrench size 7/16 in screw driver cutting pliers (a) Remove the screws from top side of composite cover between fuselage and stabilizer. (b) Remove bolts connecting the rear side attachments on the bulkhead No. 13. (c) Disconnect the trim tab actuator wires (3) (see Fig.6-8) located between the stabilizer and fuselage.

  • Page 51: Elevator Assembly

    Tools needed: wrench size 7/16 in cutting pliers (a) Remove the cover (1) from the access hole (2) (see Fig.6-8). (b) Disconnect the trim tab actuator wires (3). (c) Remove the fibreglaas cover (6) (see Fig.5-2). (d) Disconnect the elevator control rod. (e) Disconnect the bolts from all three hinges (4) (see Fig.5-1).

  • Page 52: Trim Tab Installation

    5.3.6 Trim tab installation Type of maintenance: heavy Authorization to perform: Repairman (LS-M) or Mechanic (A&P) . Tools needed: pliers, cutting pliers pliers for riveting (a) Insert the trim tab with piano hinge to the elevator. (b) Rivet the piano hinge into the elevator. (c) Check for free rotation of the trim tab.

  • Page 53: Check / Adjustment

    Check / Adjustment No procedures included. Exchanges / Service information No procedures included. 5 - TAIL UNIT Date of issue: 04/2009 Revision No.5 5 - 7...
  • Page 54 INTENTIONALLY LEFT BLANK...

  • Page 55: Chapter 6 - Controls

    CHAPTER 6 - CONTROLS General ........................6-2 Description and operation..................6-2 6.2.1 Lateral control (aileron control).............. 6-2 6.2.2 Longitudinal control (elevator control) ........... 6-3 6.2.3 Directional control (rudder control) ............6-3 6.2.4 Elevator trim tab control................. 6-4 6.2.5 Wing flap control..................6-5 Removal / Installation ....................

  • Page 56: General

    6.1 General SPORTCRUISER airplane is equipped with dual controls which enables pilot training. Airplane control includes: lateral control (aileron control) • longitudinal control (elevator control) • directional control (rudder control) • aileron trim tab control • elevator trim tab control •...

  • Page 57: Longitudinal Control (Elevator Control)

    6.2.2 Longitudinal control (elevator control) The elevator is controlled by control sticks. Movement of control sticks is transferred by system of transmission levers and push rods to the elevator. Forward and backward movement of the control stick is transferred by the push rod lead through the central channel between seats to the two-arm lever which is located under the baggage floor.

  • Page 58: Elevator Trim Tab Control

    Fig. 6-3: Directional control 6.2.4 Elevator trim tab control The elevator trim tab is controlled by the electrical actuator installed in elevator and connected per threaded rod with trim tab. Control switches are integrated part of grip on the left control stick (option on both control sticks).

  • Page 59: Wing Flap Control

    6.2.5 Wing flap control Wing flaps are controlled by an electric flaps actuator connected with flaps per torque tube with control pins on each end. The flaps actuator located in fuselage under floor of baggage space and is controlled by a rocker switch located in cockpit. A LED position indicator is installed together with the rocker swich on the middle channel under instrument panel.
  • Page 60 Grease bearings with lubricant grease before installing the push rods into airplane unless otherwise stated by the bearing manufacturer. Do not grease nor rinse the bearings with permanent filing that are covered by metal or plastic covers. Do not rinse bearings and articulated joints with technical gasoline.

  • Page 61: Control Stick Removal

    Tools needed: wrench size 7/16 in, 3/8 in pliers Installation of the control sticks is shown on Fig. 6-6. (a) Put the stick (4) in the torque tube (2). (b) Turn the stick (4) 90 degree and insert the bolt (10) in to the torque tube and stick. (c) Put the control stick assembly (9) in the hinges (7) on the cabin floor (8).

  • Page 62: Removal Of Wing Flap Control Actuator

    6.3.4 Removal of wing flap control actuator Type of maintenance: line Authorization to perform: Repairman (LS-M) or Mechanic (A&P) Tools needed: wrench size 7/16 in, 1/2 in, screwdriver Removal of the flap control actuator is shown on Fig. 6-7. (a) Open the cover behind the left seat (1) on the floor of baggage space. (b) Move the flap (2) to the landing position.

  • Page 63: Removal Of The Trim Tab Control Actuator

    Installation of flap control lever is shown on Fig. 6-7. (a) Insert flap actuator (4) in to the actuator hinge (6). (b) Connect actuator wire (5). (c) Connect the flap actuator (4) with the flap lever (3). (d) Check the flap operation and deflections (see 6.4.3). (e) Close the cover on the floor of baggage space.

  • Page 64: Installation Of The Trim Tab Control Actuator

    6.3.7 Installation of the trim tab control actuator Type of maintenance: heavy Authorization to perform: Repairman (LS-M) or Mechanic (A&P) . Tools needed: wrench size No.5 screwdriver pliers (a) Insert trim tab actuator (6) in to the elevator or aileron through access hole (2). (b) Connect the actuator (6) from the elevator or aileron skin.

  • Page 65: Removal Of Aileron Control Bellcrank In The Wing

    1 … Control lever 2 … Bolt 3 … Bolt 4 … Lever bracket 5 … Rod Fig. 6-9: Control lever of aileron control behind the seats 6.3.10 Removal of aileron control bellcrank in the wing Type of maintenance: heavy Authorization to perform: Repairman (LS-M) or Mechanic (A&P) .

  • Page 66: Installation Of Aileron Control Bellcrank In The Wing

    1 ... Cover 3,4 ... Rods 5,6 ... Rod bolts 7 ... Bellcrank 8 ... Bellcrank bolt Fig. 6-10: Bellcrank of aileron control 6.3.11 Installation of aileron control bellcrank in the wing Type of maintenance: heavy Authorization to perform: Repairman (LS-M) or Mechanic (A&P) . Tools needed: wrench size 7/16 in screwdriver...
  • Page 67 6.3.12 Removal of two-arm levers in front fuselage Attachments of the two-arm levers are shown on Fig. 6-11. 6.3.12.1 Removal of front two-arm lever Type of maintenance: heavy Authorization to perform: Repairman (LS-M) or Mechanic (A&P) . Tools needed: wrench size 7/16 in screwdriver pliers (a) Remove the cover on the floor of baggage compartment (1).
  • Page 68 1 ... Cover on the floor of bagg. comp. 5 … Rear middle channel cover 2 ... Push rod end 6 … Rear two-arm lever 3 ... Front two-arm lever 7 … Rear two-arm lever hinge 4 ... Front two-arm lever hinge Fig.

  • Page 69: Removal Of The Two-Arm Lever In Rear Fuselage

    (c) Connect both push rod ends (2) with the two-arm lever (3). (d) Close the access hole on the baggage compartment floor by cover. (e) Check elevator deviations (see 6.4.3) and check control plays (see 6.4.1). 6.3.13.2 Installation of rear two-arm lever Type of maintenance: heavy Authorization to perform: Repairman (LS-M) or Mechanic (A&P) .

  • Page 70: Installation Of The Two-Arm Lever In Rear Fuselage

    1 ... Cover 4 ... Bolt 2 ... Push rod end 5 ... Lever bracket 3 ... Two-arm lever 6 ... Bolt Fig. 6-12: Two-arm lever – rear fuselage 6.3.15 Installation of the two-arm lever in rear fuselage Type of maintenance: heavy Authorization to perform: Repairman (LS-M) or Mechanic (A&P) .

  • Page 71: Check / Adjustment

    6.4 Check / Adjustment 6.4.1 Check of plays in control Admissible plays in control are mentioned in the following table: Control Admissible play Area to measure play at the end of the control stick in longitudinal axis of longitudinal max 4mm (5/32 in) the airplane at the end of the control stick in lateral axis of the lateral...
  • Page 72 Fig. 6-13: Play in longitudinal control Lateral control Measure play at the end of the control stick by the measuring instrument from the fuselage side at blocked ailerons in the neutral position. First block the right aileron and measure play on the control stick, then measure play at the blocked left aileron.

  • Page 73: Check For Friction In Control System

    Measure force at the moment of rudder deflection from the neutral position. Max force can be 4 kg (8,8 lbs). 6.4.3 Checking control surface deflections Control surface deflections of SPORTCRUISER are shown in the following table: Valid for S/N 06SC001 Valid for S/N 08SC134...
  • Page 74 For measuring deflections use protractor with deflecting pointer that will be attached to an appropriate control surface by means of the clamp. Measuring aileron deflections (a) Attach the protractor with the deflecting pointer on the upper skin of the aileron by means of the clamp.

  • Page 75: Adjustment Of Control Surface Deflections

    Measuring trim tab deflections (a) Set the protractor with the deflecting pointer to the trailing edge of the trim tab by means of the clamp. (b) Set the trim tab to neutral position. (c) Set the protractor to 0° - starting value of me asuring. (d) By means of the trim control actuator deflect the trim tab to extreme positions and read the deflection.

  • Page 76: Exchanges / Service Information

    Adjusting rudder deflections Rudder deflections are given by setting the stops on the rudder control lever installed on root rudder rib. (a) Set the foot control pedals to neutral position and check if the rudder is in the neutral position. (b) Carry out correction of rudder deflection setting by adjusting the turnbuckles on the foot pedal side in cockpit.
  • Page 77 Note: Grease the new cable with lubricant grease before installing it to the fuselage. (d) Insert the new cable from the rudder side into the fuselage. (e) Set nicopress sleeve (5) on the cable end in cockpit. (f) Bend the cable end in cockpit around the cable thimble (6), insert the turnbuckle eye to the cable thimble, set nicopress sleeve (5) close to the cable thimble and press nicopress sleeve by Nicopress pliers (see 15.10).
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  • Page 79: Chapter 7 - Equipment

    CHAPTER 7 - EQUIPMENT General ........................7-2 Description and operation..................7-2 7.2.1 Seats...................... 7-2 7.2.2 Safety harnesses................... 7-3 Removal / Installation .................... 7-3 7.3.1 Removal of seats.................. 7-3 7.3.2 Removal of safety harnesses ..............7-3 7.3.3 Installation of safety harnesses ............. 7-3 Check / Adjustment....................

  • Page 80: General

    • Description and operation 7.2.1 Seats Seats (1) of the SPORTCRUISER airplane are fixed and are equipped with an upholstered removable cushions attached on Velcro. The seat backs (2) are attached to the bulkhead No.4 per piano hinge (3). 1 ... Seat 3 ...

  • Page 81: Safety Harnesses

    7.2.2 Safety harnesses Seats are equipped with safety harnesses (4). Safety harnesses consist of two lap straps, two shoulder straps and a safety harness lock. Length of the lap straps and the shoulder straps is adjustable. Removal / Installation 7.3.1 Removal of seats (a) Remove the seats from the velcro, (b) Seat back is not removable.

  • Page 82: Check / Adjustment

    1 ... Attachment bracket 2 ... Bolt Fig. 7-2: Removal/Installation of safety harnesses 7.4 Check / Adjustment 7.4.1 Checking of safety harnesses Check harnesses surface for any damages. Check the lock system function. Check the attachment points of shoulder and side harnesses for any damages or corrosion. 7.5 Exchanges / Service information 7.5.1 Cleaning seat covers and upholstery (a) Take upholstery and covers out of the airplane.

  • Page 83: Chapter 8 - Landing Gear

    CHAPTER 8 – LANDING GEAR General ........................8-2 Description and operation..................8-2 8.2.1 Main landing gear .................. 8-2 8.2.1.1 Main landing gear wheel ............ 8-3 8.2.2 Nose landing gear ................. 8-3 8.2.2.1 Nose landing gear wheel ........... 8-4 8.2.3 Brake system..................8-5 8.2.3.1 Parking brake..............

  • Page 84: General

    General SPORTCRUISER airplane landing gear is of three-wheel fixed design and consists of the main landing gear and the nose landing gear. The nose landing gear is not steerable. The main landing gear wheels are equipped with hydraulic disk brakes.
  • Page 85 Fig. 8-2: Landing gear wheel 8.2.2 Nose landing gear The nose landing gear of SPORTCRUISER airplane is not steerable and consists of 4130 steel welded landing gear leg (1), aluminum fork with doubler (2), shock absorber (3) and the wheel (4). The landing gear is attached to the brackets (5) installed on the bulkhead No. 1.

  • Page 86: Nose Landing Gear Wheel

    1 ... Landing gear leg 4 ... Nose landing gear wheel 2 ... Wheel fork with doubler 5 ... Attachment brackets 3 ... Shock absorber Fig. 8-4: Nose landing gear scheme 8.2.2.1 Nose landing gear wheel The nose landing gear wheel rim is pressed of aluminum. In order to facilitate assembly and disassembly of tires, the rim is split.

  • Page 87: Brake System

    8.2.3 Brake system SPORTCRUISER airplane is equipped with hydraulic disc brakes on the main landing gear wheels. Brake system consists of the brake pedals (part of rudder control pedals, see Fig. 8- 7), brake pumps, hoses for brake fluid supply, brake calipers and brake pads. By depressing pedals, brake pumps are compressed and pressure generated in the brake circuit and the calipers pushes the brake pads onto the brake disks.

  • Page 88: Removal Of Main Landing Gear Wheel

    8.3.3 Removal of main landing gear wheel Type of maintenance: line Authorization to perform: Sport pilot or higher Tools needed: socket wrench size 1 1/2 in allen wrench size 3/16 in pliers The main landing gear wheel assembly consists of the wheel rim, the tube, the tire, the brake disc and the brake.

  • Page 89: Installation Of Nose Landing Gear Wheel

    Tools needed: wrench size 1 1/8 in pliers At removing proceed according to Fig. 8-5: (a) Jack and support the airplane (see 14.2) (b) Disassemble wheel fairing (see 8.3.1) (b) Remove the cotter pins (4) securing nuts (3) on wheel axle (5). (c) Remove the nuts (3) from wheel axle (5).

  • Page 90: Installation Of The Main Landing Gear Leg

    1 ... Brake line 4 ... Bolt 2 ... Main gear leg 5 … Attachment channel 3 ... Stirrup Fig. 8-7: Removal / Installation of the main landing gear leg 8.3.8 Installation of the main landing gear leg Type of maintenance: heavy Authorization to perform: Repairman (LS-M) or Mechanic (A&P) .

  • Page 91: Installation Of Nose Landing Gear Leg

    At removing proceed according to Fig. 8-8. (a) Jack and support the airplane, (see section 14.2). (b) Remove the bolts (3) from the leg brackets. (c) Disconnect shock absorber from the shock absorber attachments (2). (d) Remove the gear leg (1) from the fuselage and put it on a suitable place. 8.3.10 Installation of nose landing gear leg Type of maintenance: heavy Authorization to perform:...

  • Page 92: Removal Of Brake Pumps

    8.3.11 Removal of brake pumps Type of maintenance: line Authorization to perform: Sport pilot or higher Tools needed: wrench size 1/2 in, 3/8 in At removing proceed according to Fig. 8-9. (a) From the brake system drain brake fluid. Disconnect the brake system hose from the brake cylinder on the main landing gear wheel and let brake fluid drain to a previously prepared can from that system line in which you want to remove the brake pump.

  • Page 93: Check / Adjustment

    1 ... Brake pump 4 ... Bracket 2 ... Brake hose 5 ... Rudder pedal 3 ... Bolts, nuts, washers Fig. 8-9: Removal / Installation of brake pumps 8.4 Check / Adjustment 8.4.1 Check of nose landing gear shock absorber a) Several times hoist and lower the nose landing gear of the airplane.

  • Page 94: Tire Change

    Changes / Service infor mation 8.5.1 Tire change Type of maintenance: line Authorization to perform: Sport pilot or higher Tools needed: wrench size 1/2 in Allen wrench size 1/4 in (a) Jack and support the airplane (see section 14.2). (b) Remove the wheel fairing (see 8.3.1). (c) Remove the main landing gear wheel (see 8.3.3) or the nose landing gear wheel (see 8.3.5).

  • Page 95: Exchange Of Brake Pads

    8.5.2 Change of nose landing gear springing elements Type of maintenance: heavy Authorization to perform: Repairman (LS-M) or Mechanic (A&P) . Tools needed: wrench size 1/2 in At changing proceed according to Fig. 8-12. (a) Disconnect shock absorber (1) from the bracket (2) on the firewall. (b) Jack and support the airplane (see section 14.2) (c) Turn shock absorber (1) forward and remove springing elements (3).
  • Page 96 Caution: Exchange always both brake pads! At changing proceed according to Fig. 8-13. (a) Jack and support the airplane (see section 14.2) (b) Remove the main landing gear wheel (see 8.3.3) (c) Remove bolts holding the pads (2) on the caliper (3) and pull out the brake pads (2) and brake disc.

  • Page 97: Refilling / Exchanging Brake Fluid

    8.5.4 Refilling / exchanging brake fluid Draining brake fluid from brake system Type of maintenance: line Authorization to perform: Sport pilot or higher Tools needed: wrench size 7/16” (a) Disconnect the brake hose from the brake cylinder and let brake fluid drain into the previously prepared can.
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  • Page 99: Chapter 9 - Fuel System

    CHAPTER 9 – FUEL SYSTEM General ........................9-2 Description and operation..................9-2 9.2.1 Fuel storage................... 9-2 9.2.2 Fuel distribution ..................9-2 9.2.3 Indication of fuel quantity and pressure..........9-3 Removal / Installation .................... 9-3 9.3.1 Fuel tank removal .................. 9-3 9.3.2 Fuel tank installation................

  • Page 100: General

    Fuel system serves for storing fuel in the airplane and its delivering to the engine. The fuel system of SPORTCRUISER airplane consists of the following parts: two fuel tanks, fuel tubing, selector valve, fuel filter, gascolator, mechanical fuel pump (located on the engine), electrical fuel pump, fuel gauge, fuel pressure gauge and drain valves of the fuel tanks.

  • Page 101: Indication Of Fuel Quantity And Pressure

    The ANDAIR selector valve (4) served also for interruption of fuel supply in case of engine fire or after long-time parking airplane. The ANDAIR selector is located on the middle console between the seats in the cockpit. The gascolator (5) is located on the firewall in lowest point of fuel system.

  • Page 102: Fuel Tank Installation

    Tools needed: wrench size No. 8, 1/2 in, screwdriver drill diam. 3.2 mm (1/8 in), 4.1 mm (5/32 in) electric drill cutting pliers, pliers (a) Disconnect the battery. (b) Drain fuel from the fuel system by the tank drain valve. (c) Unscrew the filler cap.

  • Page 103: Removal Of The Finger Screen

    9.3.3 Removal of the finger screen Type of maintenance: line Authorization to perform: Repairman (LS-M) or Mechanic (A&P) Tools needed: screwdriver At removing proceed according to Fig. 9-4. The finger screen is located in the root tank rib. (a) Drain fuel from the fuel system. (b) Remove the wing –...

  • Page 104: Fuel Level Sender Removal

    9.3.5 Fuel level sender removal Type of maintenance: line Authorization to perform: Sport pilot or higher Tools needed: electric drill drill diam. 3.2 mm (1/8 in) screwdriver cutting pliers, pliers (a) Remove (drill off) the fuel level sender cover plate. (b) Disconnect fuel level sender wire.

  • Page 105: Fuel Drain Valve Removal

    Fig. 9-5: Float mechanism 9.3.7 Fuel drain valve removal Type of maintenance: line Authorization to perform: Sport pilot or higher Tools needed: wrench size 1/2 in (a) Drain the fuel from the tank or gascollator. (b) Remove drain valve from the tank or gascollator - unscrew it. (c) Check “O”...

  • Page 106: Fuel Pump Check

    Checking airplane fuel system tightness by air (a) Connect an appropriate device to the filing neck for pressurizing. (b) Blind the fuel filter by plugs. Blind the fuel tank venting with the rubber plug (or from a similar material) and secure it with locking wire. (c) ANDAIR selector valve - ON position –...
  • Page 107 Safety instructions for filling fuel into the airplane tanks (a) The fuel tanks can be filed with fuel only by persons who are fully instructed and familiarized with safety instructions. (b) It is prohibited to fill the fuel tank: during rain and storm •...
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  • Page 109: Chapter 10 - Power Unit

    CHAPTER 10 – POWER UNIT 10.1 General ........................ 10-3 10.2 Description and operation..................10-3 10.2.1 Engine ....................10-3 10.2.1.1 Engine mount..............10-4 10.2.1.2 Engine cowling..............10-5 10.2.1.3 Engine control ..............10-5 10.2.1.4 Engine instruments ............10-6 10.2.1.5 Engine cooling system ............. 10-6 10.2.1.6 Engine lubrication system ..........
  • Page 110 10.5 Exchanges / Service information ............... 10-27 10.5.1 Exchange / Refilling oil ..............10-27 10.5.2 Exchange / Refilling cooling liquid............. 10-28 10.5.3 Exchange / Check of oil filter ............. 10-28 10.5.4 Exchange / Check of air filter ............10-29 10 - POWER UNIT Date of issue: 04/2009 Revision No.5 10 - 2...

  • Page 111: General

    10.1 General Standard power unit of SPORTCRUISER airplane is the ROTAX 912ULS engine and Woodcomp Klassic 170/3/R in ground adjustable 3-blade propeller. 10.2 Description and operation 10.2.1 Engine The engine ROTAX 912 ULS is a four-stroke, four-cylinder, opposed - cylinder engine, central cam shaft and OHV - mechanism with maximal power of 73.5 kW ( 98.6 hp ) at...

  • Page 112: Engine Mount

    (refer to the Rotax Operator’s manual section 10.2.2 Fuel, Rotax Service Instructions SI-912-016) MOGAS European standard - min. RON 95, EN 228 Super, EN 228 Super plus US standard - ASTM D4814 Canadian standard - min. AKI 91, CAN/CGSB-3.5 Quality 3 AVGAS US standard - AVGAS 100 LL (ASTM D910) AVGAS 100 LL places greater stress on the valve seats due to its high lead content and...

  • Page 113: Engine Cowling

    10.2.1.2 Engine cowling The engine cowling (Fig. 10-2) consists of two parts: upper cowling and lower cowling. The upper cowling (1) is attached by means of quick fasteners (4) to the fire wall and to the lower cowling (2). Unlock the quick fasteners by turning the bolt by 90° counter- clockwise.

  • Page 114: Engine Instruments

    max. take-of power. Engine power control lever is mechanically connected (by cable) to the carburetors. If the control lever is fully pushed, this position corresponds to max. take-of power of the engine. If the control lever is fully pulled, this position corresponds to idle. Changes in the engine power setting can be made by moving of the control lever forward and backward.

  • Page 115: Air Inlet System Of The Engine

    from the oil tank (4) located on the fire wall through the oil cooler (5) and the oil pump with oil filter (1) to the lubricated points on the engine. The oil pump is equipped with the pressure regulator and with the pressure transmitter. The oil tank is ventilated by the hose (6) which is led under the airplane.

  • Page 116: Exhaust System

    10.2.1.8 Exhaust system Exhaust system of SPORTCRUISER airplane consist of four exhaust pipe (1) branches which lead exhaust gases from individual cylinders to the muffler (2). The muffler serves at the same time as a silencer. Exhaust gases are led from there by the exhaust pipe (3) down the airplane.

  • Page 117: Ignition System

    1 ... Exhaust pipes 4 ... Spring 2 ... Muffler 5 ... Heat exchanger 3 ... Outlet exhaust pipe 6 ... Spring Fig. 10-6: Exhaust system 10.2.1.9 Ignition system The engine is equipped with the double contactless ignition system. Every ignition circuit has its source of energy, control unit, 2-ignition coils and 4-spark plugs.

  • Page 118: Propeller

    Fig. 10-7: Ignition selection switch 10.2.2 Propeller The propeller WOODCOMP KLASSIC 170/3/R is a three-blade ground adjustable composite propeller designed for the airplanes with piston engines with power up to 73.5 kW (98.6 hp) and max. propeller speed up to 2360 rpm. The leading edge of the propeller blades is protected from damaging on the outer side by polyurethane tape.

  • Page 119: Installation Of The Engine On The Airplane

    (h) Remove the oil cooler (see 10.3.9) and the radiator (see 10.3.11). (i) Disconnect control of carburetors and carburetors heating. (j) Remove air intake (see 10.3.5). (k) Remove the exhaust system (see 10.3.7). (l) Blind all the holes on the engine so that no impurity can get into the engine. (m) Cut of the wire securing the screw heads (3).
  • Page 120 1 ... Engine mount 6 ... Cotter pin 9 ... Silentblock 3 ... Screw 7 ... Bolt 10 ... Spacer 4 ... Washer 8 ... Dynafocal bracket 11 ... Washer Fig. 10-8: Engine mount attachment to the engine and to the firewall (c) Install the exhaust system (see 10.3.8).

  • Page 121: Removal Of The Propeller

    1 ... Carburetor 4 ... Choke control cable 2 ... Mixing chamber 5 ... Throttle control lever 3 ... Throttle control cable 6 ... Choke control lever Fig. 10-9: Choke and throttle control connection 10.3.3 Removal of the propeller Type of maintenance: line Authorization to perform: Repairman (LS-M) or Mechanic (A&P) Tools needed:...

  • Page 122: Installation Of The Propeller

    1 ... Propeller spinner 5 ... Propeller spinner flange 2 ... Propeller hub 6 ... Washer 3 ... Spacer 7 ... Bolt 4 ... Propeller flange on the engine 8 ... Nut Fig. 10-10: Propeller removal / installation 10.3.4 Installation of the propeller Type of maintenance: line Authorization to perform: Repairman (LS-M) or Mechanic (A&P)
  • Page 123 step - by toque of 5 Nm (3.7 ft.lb.) step - by torque of 10 Nm (7.4 ft.lb.) step - by torque of 16 Nm (11.8 ft.lb.) Fig. 10-11: Bolt tightening sequence (e) Remove spark plugs of the engine and secure the airplane against its movement (see 14.5).

  • Page 124: Air Intake System Removal

    10.3.5 Air intake system removal Type of maintenance: line Authorization to perform: Sports pilot or higher Tools needed: wrench size No.8, No.10 Screwdriver See the Fig. 10-13. (a) Remove the upper engine cowling. (b) Disconnect the control cable (6) from the air intake changeover lever (4) and from the holder.

  • Page 125: Exhaust System Removal

    1 ... Airbox 10 ... Air hose - preheated air 4 ... Air intake changeover lever 11 ... Muffler 6 ... Control cable 12 ... Lower engine cowling 7 ... Hose interconnecting airbox 13 ... Hose fastener and the carburetor 14 ...

  • Page 126: Exhaust System Installation

    10.3.8 Exhaust system installation Type of maintenance: line Authorization to perform: Repairman (LS-M) or Mechanic (A&P) Tools needed: wrench size No.13 pliers small wire hook (spring removal/assembly jig) See the Fig. 10-6. (a) Install the exhaust pipes (1) to the engine necks. Mind a proper arrangement, each pipe is designed for specific necks.

  • Page 127: Removal Of The Radiator

    Tools needed: wrench size No.19, No.30 See the Fig. 10-4. (a) Set the oil cooler to the bracket on the engine mount and on the cooler necks gradually install and tight the nuts. Install the banjo with oil hoses, screw the banjo bolts and secure this bolts with the locking wire (see 15.8.2).
  • Page 128 1 ... Radiator 3 ... Lower bracket 2 ... Upper brackets 4 ... Shock absorbers Fig. 10-14: Attachment of the radiator on the engine 10.3.13 Removal of the throttle and choke control levers Type of maintenance: line Authorization to perform: Repairman (LS-M) or Mechanic (A&P) Tools needed: wrench size No.14...
  • Page 129 1 ... Throttle handle 3 ... Throttle cable 2 ... Choke handle 4 ... Choke cable Fig. 10-15: Throttle control lever 10.3.14 Installing of the throttle and choke control levers Type of maintenance: line Authorization to perform: Repairman (LS-M) or Mechanic (A&P) Tools needed: wrench size No.14 Allen wrench size No.

  • Page 130: Removal Of The Carburetor Heating Knob

    10.3.15 Removal of the carburetors heating knob Type of maintenance: line Authorization to perform: Sports pilot or higher Tools needed: wrench size No.8, No.14 Screwdriver Cutting pliers See the Fig. 10-17. (a) Remove the upper engine cowling. (b) Disconnect the control cable on the changeover lever of the air intake (4) (see the Fig. 10-13).

  • Page 131: Check / Adjustment

    ROTAX 912 ULS. In the course of the whole test an aircraft mechanic who is familiarized with the aircraft type SPORTCRUISER must be present. (a) Perform the test out of the buildings at the place assigned for performing engine tests in broad daylight.
  • Page 132 Note: RPM drop between position BOTH and L or R must not exceed 300 RPM. Mutual difference between ignition circuits L and R must not exceed 120 RPM. Write down results into the engine test report, see the tab. 10-1. (i) Test of max.
  • Page 133 ENGINE TEST REPORT Aircraft SportCruiser Registration Serial No. Engine ROTAX 912 ULS Serial No. Activity Set down values Measured values Starting up the engine Min. oil pressure up to 10 sec. 0.8 bar (12 psi) Max. oil pressure* 7 bar (102 psi) Min.

  • Page 134: Adjusting Throttle Control

    10.4.2 Adjusting throttle control (a) Pull the throttle control to the stop. The throttle lever on the carburetor (5) must be on the stop (see Fig. 10-9). The bowden must be supported in the terminals. (b) Release the nut on the control lever (5) and take up any slack on the cable and tighten up the nut.

  • Page 135: Exchanges / Service Information

    Check the exhaust system for cracks. Pay special attention to the following areas: muffler in the area of the input and the output pipe and the collector head • all welds and their immediate surrounding • carefully check al areas showing local overheating caused by exhaust gases. •...

  • Page 136: Exchange / Refilling Cooling Liquid

    Venting of the lubrication system After short idling , stop engine and replenish oil to max. mark on dipstick. Never overfill, otherwise oil would escape throughthe vent tube during operation. At oil level inspect, do not exceed the max. mark. 10.5.2 xchange / Refilling cooling liquid - refer to the Rotax Maintenance manual Chapter 12-00-00 section 3 Cooling system...

  • Page 137: Exchange / Check Of Air Filter

    10.5.4 Exchange / Check of air filter (a) Remove the hose fastener and the bracket attaching the air filter to the left side lower engine cowling and remov the air filter. (b) Inspect the air filter and if contaminated, clean it according to instructions in the Rotax Maintenance manual Chapter 12-00-00 section 2.4.
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  • Page 139: Chapter 11 - Electrical System

    CHAPTER 11 – ELECTRICAL SYSTEM 11.1 General ........................ 11-2 11.2 Description and operation..................11-2 11.2.1 Switches ....................11-2 11.2.2 Circuit breakers ................... 11-3 11.2.3 Generator ................... 11-4 11.2.4 Onboard battery................... 11-4 11.2.5 Lighting ....................11-4 11.2.5.1 Optional instrument lighting ..........11-5 11.2.5.2 Optional external lighting ..........

  • Page 140: Description And Operation

    11.1 General Electrical system of SPORTCRUISER airplane serves for supplying electrical current to the instruments. 11.2 Description and operation The airplane is equipped with 14V DC electrical installations with grounded negative pole. Primary source of electrical energy is formed by the generator. The secondary source of electrical energy is the battery 12V, which is located on the firewall.

  • Page 141: Circuit Breakers

    Switches Designation Description Switch of radio, intercom, transponder, AVIONICS GPS and other optional avionics. FLAPS Switch of flaps control. TRIM Switch of trim control. Switches-circuit breakers Designation Description Current rating MASTER Main switch. INSTR Switch of engine instruments. FUEL PUMP Switch of electric fuel pump.

  • Page 142: Generator

    11.2.3 Generator The generator is a part of the engine which supplies electric current through the rectifier. Regulator supplies electric current of 14V voltage to onboard network. Technical parameters of generator: Maximum output power: 12V/20A at 5000 rpm Technical parameters of rectifier - regulator: Type: electronic Output voltage:...

  • Page 143: Optional Instrument Lighting

    11.2.5.1 Optional instrument lighting Instruments on the instrument panel can be equipped with light rings which in the case of need can be switched on by the switch INSTR LIGHT on the instrument panel. 11.2.5.2 Optional external lighting External lighting consists of optional position and strobe lights which are located in the wing tips and of the optional landing light which is located in the leading edge of the wing.

  • Page 144: Removal Of The Optional Strobe/Position Lights

    11.3.3 Removal of the optional strobe/position lights Type of maintenance: line Authorization to perform: - Sports pilot or higher Tools needed: - screwdriver (a) Remove bolts attaching the cover glass of strobe/position lights. (b) Remove bolts attaching the strobe/position lights to the wing tip, thus releasing the lights.

  • Page 145: Installation Of The Optional Landing Light

    11.3.6 Installation of the optional landing light Type of maintenance: line Authorization to perform: - Sports pilot or higher Tools needed: - screwdriver (a) Set the wires into the light connector from the rear side of the bulb. (b) Set the headlight into the back plate and screw on the bulb the cover rim. (c) Adjust the landing light (see 11.4.1).

  • Page 146: Exchanges / Service Information

    11.5 Exchanges / Service information 11.5.1 Charging the battery (a) Disconnect the battery from the onboard electrical network. (b) Clean battery contacts connect charging device them. Mind the polarity! (c) Charging voltage at temperature of 20° C (68° F) is 13.8 to 14.4V (2.3 to 2.4V/cel). Maximum charging current is 8A.

  • Page 147: Exchange Of The Optional Position Light Lamp

    11.5.2 Exchange of the optional position light lamp (a) Remove the cover of the position lights including the cover glass. (b) Slightly push in the front lamp and turn it counter-clockwise (bayonet closure) and exchange it for the same type. (c) Remove the rear lamp and exchange it for the same type.
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  • Page 149: Chapter 12 - Pitot-Static System/Instruments

    CHAPTER 12 – PITOT-STATIC SYSTEM/INSTRUMENTS 12.1 General ........................ 12-2 12.2 Description and operation..................12-2 12.2.1 Pitot-static system ................12-2 12.2.2 Flight instruments ................12-3 12.2.3 Engine instruments................12-3 12.3 Removal / Installation ..................12-5 12.3.1 Removal of the pitot-static tube............12-5 12.3.2 Installation of the pitot-static tube............

  • Page 150: Description And Operation

    12.1 General This chapter provides information about pitot-static system and instruments 12.2 Description and operation 12.2.1 Pitot-static system The pitot-static tube for sensing static and total pressure is located under the left half of the wing close to the rib No.4. Total pressure is sensed through the hole in the pitot-tube face and static pressure is sensed through the holes on the tube circumference.
  • Page 151 12.2.2 Flight instruments Airspeed indicator - ASI The airspeed indicator located on the left side of instrument panel is classical analogue round pressure gauge. The airspeed indicator color range marking is shown in Tab.12-1. IAS value or range Marking Significance knot km/h White...
  • Page 152 Tachometer The RPM indicator is electrical and is controlled by the signal from the RPM sensor on the generator. Working range of the RPM indicator is from 0 to 7000 RPM. Cylinder head thermometer Cylinder head temperature sensor measures temperature of the cylinder No.3. Working range of the cylinder head thermometer is 50 to 150°...

  • Page 153: Removal / Installation

    12.3 Removal / Installation 12.3.1 Removal of the pitot-static tube Type of maintenance: line Authorization to perform: Repairman (LS-M) or Mechanic (A&P) Tools needed: screwdriver phillips #1l pliers, cutting pliers (a) Loose securing bolt in the pitot-static tube bracket and pull out a bit the pitot-static tube with hoses from the bracket.

  • Page 154: Check / Adjustment

    12.4 Check / Adjustment 12.4.1 Check of pitot-static system tightness (a) In the static pressure system create the under pressure by means of an appropriate instrument corresponding to altitude of 1000 ft. Drop in the indicated altitude per one minute must not exceed 100 ft. (b) In the system of total pressure create the overpressure corresponding to speed of 140 knots (260 km/h,161 mph) by means of a suitable instrument.
  • Page 155 REPORT OF MAGNETIC COMPASS COMPENSATION Aircraft Registration mark Serial No. Compass Type: Compass Serial No.: List of Switched-On Radionavigation Engine running Engine stopped Course Measured Deviation Measured Deviation Date: Time: Compensation conforming: YES - NO Note: Elaborated by: Signature: Date: Checked by: Signature: Date:...
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  • Page 157: Chapter 13 - Venting/Heating

    CHAPTER 13 – VENTING/HEATING 13.1 General ........................ 13-2 13.2 Description and operation..................13-2 13.2.1 Venting system ..................13-2 13.2.2 Heating System ................... 13-2 13.3 Removal / Installation ..................13-3 13.3.1 Removal of the heating control knob........... 13-3 13.3.2 Installation of the heating control knob..........13-3 13.3.3 Removal of the vents................

  • Page 158: Description And Operation

    13.1 General This chapter contains information on crew compartment heating and ventilation system. 13.2 Description and operation 13.2.1 Venting system Cockpit ventilation is ensured by two regulated air vents located on the cockpit sides under the instrument panel (see Fig.13-3). Air inlets of NACA type are located on the fuselage sides in front of the canopy frame.

  • Page 159: Removal / Installation

    13.3 Removal / Installation 13.3.1 Removal of the heating control knob Type of maintenance: line Authorization to perform: Sports pilot or higher Tools needed: wrench size No. 14, 9/16” pliers, cutting pliers See Fig. 13-2. (a) Disconnect the control cable on the control flap lever (3) (see Fig. 13-1). (b) Remove the nuts (1) thus releasing the flexible housing (3) with the heating control knob (2).

  • Page 160: Installation Of The Vents

    13.3.3 Removal of the air vents See the Fig. 13-3. (a) Open the control flap (1) 90 degree and pull the vent (2) out from the housing (3). 1 ... Control flap 2 ... Vent 3 ... Housing Fig. 13-3: Removal / Installation of the vents 13.3.4 Installation of the vents See the Fig.13-3.

  • Page 161: Chapter 14 - Airplane Handling

    CHAPTER 14 – AIRPLANE HANDLING 14.1 General ........................ 14-2 14.2 Jacking and supporting the airplane ..............14-2 14.3 Airplane towing ....................14-2 14.4 Airplane parking ....................14-3 14.5 Airplane anchoring ....................14-3 14 - AIRPLANE HANDLING Date of issue: 04/2009 Revision No.5 14 - 1...
  • Page 162 14.1 General This chapter contains information on airplane handling - jacking, parking and anchoring. 14.2 Jacking and supporting the airplane Due to the relatively low empty weight, the airplane jacking can be carried out by two persons. There are three supporting points (see Fig.14-1), two of them are under upper ends of main landing gear legs (1), third one is on bottom skin of fuselage behind nose gear leg (2).
  • Page 163 Caution: Use the parking brake only for short-term parking between flights during the day. When the flight day is over or under low air temperatures, do not use the parking brake and apply the wheel chocks instead. 14.5 Airplane anchoring When parking, the airplane outside the hangar after flight day, the airplane should be anchored to the ground.
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  • Page 165: Chapter 15 - Airplane Repairs

    CHAPTER 15 – AIRPLANE REPAIRS 15.1 General ........................ 15-3 15.2 Removing rivets ....................15-3 15.3 Riveting ........................ 15-4 15.3.1 General ....................15-4 15.3.2 Riveting procedure ................15-4 15.4 Skin repairs ......................15-5 15.4.1 Removing damaged skins ..............15-5 15.4.2 Division of damaging into groups ............15-5 15.4.3 Principles for repair method determination..........
  • Page 166 15.8 Securing the bolt joints ..................15-19 15.8.1 General ....................15-19 15.8.2 Bolt joint securing by locking wire ............. 15-19 15.8.3 Bolt joint securing by cotter pin ............15-21 15.9 Bonding repairs....................15-21 15.9.1 General ....................15-21 15.9.2 Removal and installation................. 15-21 15.10 Installing clamps by Nicopress pliers .............

  • Page 167: General

    15.1 General This chapter contains information about standard procedures for performing common repairs of the airplane. These repairs can be made by an authorized organization. Other procedures for repairing individual airplane systems you can find in the appropriate chapter describing the system. Note: Before carrying out any structural repairs to contact the relevant airworthiness authority for approval.

  • Page 168: Riveting

    General Riveted parts are used in design of SPORTCRUISER airplane for whole fuselage, wings, flaps, ailerons and tail unit. In the following table there is a survey of rivets that are used on SPORTCRUISER airplane structure. Type of rivets Designation...

  • Page 169: Skin Repairs

    (c) Damage with disturbance of basic structural elements of the aircraft. (Deformation of wing and stabilizer spar, deformation of wing ribs, fuselage bulkheads etc.). These repairs can be made only by Czech Sport Aircraft a.s. as producer or by authorized repair shop - for more detailed information contact Czech Sport Aircraft a.s.

  • Page 170: Angle Repair

    (c) Use the same material for repairs as the material of a defective area (for survey of used materials see section 17.3). (d) Carry out repair of skin damaging by means of patches having the same thickness as the original skin or higher. (e) Repair the angle defects with inserted angles with the section by 10 to 20% higher than the section of the damaged angle (see 15.4.4).

  • Page 171: Skin Repair

    15.4.5 Skin repair 15.4.5.1 Stopping cracks and blinding small holes Propagation of small cracks can be stopped by drilling a hole with the drill bit of dia 3.2 mm (1/8 in) at the utmost end of the crack. If propagation continues, repeat the drilling. Support the place of drilling with a wooden block at drilling thin skin and use the sharp drill bit so that it will not drift and will not cause another damage to the skin.
  • Page 172 Be careful that all cracks as well as adjacent corroded areas are cutted out. Corners of cut out holes in the skin must have minimum radius of 12.7 mm (0.5 in) and their edges must be smoothly filed off. Size of patch overlapping depends on the cut out of skin area : (a) patch up to the area of 51.6 cm (8 in ) - rivet by one row of rivets, the patch edge...
  • Page 173 A ... Punctured skin B ... Cutting out and cleaning the damaged skin C ... Repair with the unsunk patch D ... Repair with the sunk patch 1 ... Patch 2 ... Frame 3 ... Skin Fig. 15-5: Repair of the punctured skin 15 - AIRPLANE REPAIRS Date of issue: 04/2009 Revision No.5...

  • Page 174: Repair Of Fiberglass Parts

    15.5 Repair of fiberglass parts 15.5.1 Damage classification Any damage of parts from reinforced plastics with epoxy matrix leads to increased saturation of the matrix with humidity and subsequently to loss of properties. Therefore we recommend carry out their repair as soon as possible after the damage has occurred. Two kinds of parts are made from these materials in the airplane: structural, load-bearing parts (canopy frame) •...

  • Page 175: Medium Damage

    laid PE or PP transparent polyethylene. After proper application the layer is without bubbles. Deposit thickness is given by necessary thickness of surrounding layers (leveling) and ranges from 0.2 to 12.7 mm (0.008 to 0.5 in) in one deposit. mixing rate of time of manufacturer,...
  • Page 176 Note: In case of C/K stiffener K rovings tend to rise up from the surface at sanding - it is difficult to sand them, we recommend to use diamond sanding tool and one- way sanding. Dust removing Dust is removed by wiping with a clean and dry brush or by a vacuum cleaner. Stiffener preparation For this kind of repairs we recommend the stiffener G (glass) with plain weave, 150 g/m (0.037 lb/ft...

  • Page 177: Major Damage

    Structural parts On these parts we do not recommend to do other as small damages repair. In case of the other damage we recommend to contact Czech Sport Aircraft a.s. as manufacturer. Caution: When repairing, it is necessary to pay attention to timely repair (see the text about low of properties at humidity effect at the beginning of 15.5.1) !

  • Page 178: Bonding Rivet Heads, Big Irregularities And Material Transitions

    Advantages: fast and reliable evaporation even from the corners and borders • without additional warming Disadvantages: it must be used without other dilution (expensive); not ecological • (danger of water contamination); detrimental to health (must be carried out in an aerated area with personal protective means);...

  • Page 179: Application Of Primer (Paint)

    manufacturer, other drying (grindable) surface type name components [min] / 18° C ( 65° F ) BASF Glasurit BASF Glasurit Al–alloys polyester 801-703 (base) 965-53 (initiator) transitions BASF Glasurit BASF Glasurit epoxide – fiberglass polyester 801-703 (base) 965-53 (initiator) + Al-alloys polyester Rivet heads BASF Glasurit...

  • Page 180: Application Of Top Coat

    15.6.2.5 Application of top coat In order to reach smooth surface we recommend again carry out the paint coat by spraying (see 15.6.2.3). Topcoat serves especially for creating the coat resistant to weather and external effects for aesthetic rendering of the unit. Considering the higher loading by external effects we recommend to use top materials, exclusively two-component ones, on the acrylic- polyurethane or polyurethane basis, always with guaranteed adhesiveness to the used base coat (according to manufacturer).

  • Page 181: Small Damage

    15.6.3 Small damage 15.6.3.1 General Small damage is a deterioration of corrosion resistance. At repair the situation is made more difficult by the fact that the substrate for repair coats is not a compact surface of basic material but mostly al coats of surface protection (after sanding), of which not al are suitable for (in ageing stage) for good adhesion of paint coats.
  • Page 182 Subsequently the primer is applied according to the table 15-6. Paint coat thickness is given by necessary thickness of surrounding coats (leveling). Caution: In case that the primer was not removed by the previous step, it is not necessary to apply the primer again. The original ground primer with adhesive intercoat is enough.

  • Page 183: Securing The Bolt Joints

    15.7 Torque moments Unless otherwise prescribed, the torque moments shown in the following table can be used. When tightening follow several rules: (a) Unless specifically stated do not grease neither nut nor bolt. (b) If possible always tighten the nut. If for some space reasons it is necessary to tighten the bolt head and the scope of tightening moment is defined.
  • Page 184 1. Adjust the correct position of 6. Pull the upper wire through the holes for locking wire. hole in the other bolt. Hold the wire end by pliers tighten it firm. 2. Pull the locking wire through 7. Hold the free end of wire by the hole in one bolt to be secured.

  • Page 185: Bolt Joint Securing By Cotter Pin

    15.9.1 General In order to keep the set down values of the transition resistances between some stuctural parts of the SPORTCRUISER airplane structure, the bonding (conductive interconnection) is installed between all important parts of the fuselage structure. 15.9.2 Removal and installation Before installing the bonding remove the paint coat which protects the joint.

  • Page 186: Installing Clamps By Nicopress Pliers

    (e) On the same areas of the airplane structure install the same type of bonding which you removed. (f) After repeated bonding installation coat the remaining metallically clean surface of the contact area, as well as protruding heads of bolts and nuts with protective paint. 15.10 Installing clamps by Nicopress pliers Procedure of clamp installation by Nicopress pliers is shown on the Fig.

  • Page 187: Chapter 16 - Wiring Diagrams

    CHAPTER 16 – WIRING DIAGRAMS 16.1 General ........................ 16-2 16.2 General wiring diagram of SportCruiser aircraft ..........16-3 16.3 Wiring diagram of trims..................16-4 16.4 Wiring diagram of flaps ..................16-5 16.5 Wiring diagrams of the communication system ........... 16-6 16.6 Wiring diagram of the transponder ..............

  • Page 188: General

    16.1 General This chapter contains typical wiring diagrams of SPORTCRUISER airplane systems, navigation and communication means. Further wiring diagrams, relating to additional equipment of the airplane, are the part of additional equipment description which is mentioned in Chapter 17 - Appendices.

  • Page 189: General Wiring Diagram Of Sportcruiser Aircraft

    16.2 General wiring diagram of SportCruiser aircraft Fig. 16-1: Wiring diagram of SportCruiser aircraft 16 - WIRING DIAGRAMS Date of issue: 04/2009 Revision No.5 16 - 3...

  • Page 190: Wiring Diagram Of Trims

    16.3 Wiring diagram of trims Fig. 16-2: Wiring diagram of the aileron and elevator trim 16 - WIRING DIAGRAMS Date of issue: 04/2009 Revision No.5 16 - 4...

  • Page 191: Wiring Diagram Of Flaps

    16.4 Wiring diagram of flaps Fig. 16-3: Wiring diagram of flaps 16 - WIRING DIAGRAMS Date of issue: 04/2009 Revision No.5 16 - 5...

  • Page 192: Wiring Diagrams Of The Communication System

    16.5 Wiring diagrams of the communication system Fig. 16-4 : Wiring diagram of the radio and intercom (stereo) 16 - WIRING DIAGRAMS Date of issue: 04/2009 Revision No.5 16 - 6...

  • Page 193: Wiring Diagram Of The Transponder

    16.6 Wiring diagram of the transponder Fig. 16-5: Wiring diagram of the transponder and encoder 16 - WIRING DIAGRAMS Date of issue: 04/2009 Revision No.5 16 - 7...

  • Page 194: Wiring Diagram Of The Gps

    16.7 Wiring diagram of the GPS Fig. 16-6: Wiring diagram of the GPS 16.8 Wiring diagram of the socket Fig. 16-7: Wiring diagram of the socket 16 - WIRING DIAGRAMS Date of issue: 04/2009 Revision No.5 16 - 8...

  • Page 195: Wiring Diagram Of The Lighting System

    16.9 Wiring diagram of the lighting system Fig. 16-8: Wiring diagram of the lighting system 16 - WIRING DIAGRAMS Date of issue: 04/2009 Revision No.5 16 - 9...
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  • Page 197: Chapter 17 - Appendices

    CHAPTER 17 - APPENDICES 17.1 General ......................17-2 17.2 List of appendices..................... 17-2 17.3 List of used material for airframe production ........... 17-3 17.4 Airplane failure card..................17-4 17.5 Operating liquids....................17-5 17 - APPENDICES Date of issue: 04/2009 Revision No.5 17 - 1...
  • Page 198 17.1 General This chapter contains other information necessary to maintain the SPORTCRUISER airplane in the form of appendices. 17.2 List of appendices Title 17.3 List of used materials 17.4 Airplane failure card 17.5 Operating liquids 17 - APPENDICES Date of issue: 04/2009 Revision No.5...
  • Page 199 17.3 List of used materials for airframe production Prescribed material 2024 T351 Duraluminium 6061 T6 Duraluminium 4130 N Steel 11 353 Steel 17240.4 Stainless steel D 671 Stainless steel 17 - APPENDICES Date of issue: 04/2009 Revision No.5 17 - 3...
  • Page 200 17.4 Airplane failure card CZECH SPORT AIRCRAFT a.s. Na Záhonech č.e.212, 686 04 Kunovice, Czech Republic Airplane Failures Card Dear customer, We would like to ask you for your assistance at obtaining information for continuous increasing reliability of airplanes produced by our company. Please fill out the card in case of any failure on your airplane.
  • Page 201 17.5 Operating liquids Aircrafts manufacturer used this operating liquids : Engine oil AeroShell Oil Sport Plus 4 Coolant VIP ANTIFREEZE C (VW TL 744C-G11) + WATER, mixture ratio coolant/water 50/50 [%] -40° C → +120° C Hydraulic (brake) fluid AeroShell Fluid 41 (Mil-H-5606, DOT5) 17 - APPENDICES Date of issue: 04/2009 Revision No.5...
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